Insulating board and plaster base



P 1940. e. R. EICHELBIERGER El AL 2,215,241

INSULATING BOARD AND PLASTER BASE Filed Jan. 23, 1939 Patented Sept. 17, 1940 UNITED STATES PATENT OFFICE 2,215,241 INSULATING BOARD AND PLASTER BASE poration of Ohio Application January 23, 1939, Serial No. 252,294

14 Claims.

This invention pertains to a plaster base assembly for building wall and ceiling construction as a support for plaster in lieu of customary wooden or metallic lath, and more particularly to a plaster board of corrugated fibrous material.

The fiber board material forming the subject matter hereof possesses high heat and sound insulating characteristics and is of vapor and moisture repellant character, the surface of which is sufficiently porous and absorbent to enable a close union therewith of an applied coating of plaster. To increase its insulating qualities and exclude moisture from the interior of the assembly, the terminals of the corrugation channels are sealed transversely of the corrugations, thereby converting the channels thereof into dead air cells.

The object of the invention is to improve the quality and characteristics of insulating board and plaster base, which may not only be economically manufactured, but will be highly efficient in use, of light weight, strong, rigid and durable, and of moisture and vaporproof character.

A further object of the invention is to provide dead air cells within the corrugation channels of such corrugated fiber board product without adding additional material or weight thereto.

A further object of the invention is to render such corrugated board vapor and moisture proof.

A further object of the invention is to provide an insulating board or plaster base embodying the advantageous structural features and inherent meritorious characteristics herein mentioned.

With the above primary and other incidental objects in. View as will more fully appear in the specification, the invention intended to be protected by Letters Patent consists of the features of construction, the parts and combinations thereof, and the mode of operation, or their equivalents, as hereinafter described or illustrated in the accompanying drawing.

In the drawing, wherein is shown the preferred but obviously not necessarily the only form of embodiment of the invention, Fig. 1 is a perspective View of a portion of insulating board and plaster base partly broken away embodying the present invention.

Fig. 2 is an enlarged sectional view thereof.

Fig. 3 is a sectional View on an enlarged scale at right angle to that of Fig. 2.

Fig. 4 illustrates the application of the finished board to a building structure.

Like parts are indicated'by similar characters of reference throughout the several views.

Broadly stated, the present insulating or plaster board comprises an assembly of superposed corrugated sheets of fibrous material and flat liner sheets thereof, adhesively united in alternating relation. The corrugated sheets or liner 5 sheets or both may comprise multiplies, between which is interposed a continuous stratum of vapor and moisture resistant material coextensive with such sheets. The margins of the assembly transversely of the corrugations are sealed by 10 joining the margins of the exterior cover sheets about the intermediate corrugated-filler portion, thereby converting the corrugation channels into vdead air spaces.

Referring to the drawing, the fiber board I, 15 comprising the subject matter hereof, comprises one or more corrugated sheets 2 interposed between two or more parallel relatively spaced fiat liner sheets 3 and fixedly united thereto by adhesive contact of the opposite crowns of the 20 corrugations with the respective fiat liner sheets 3. Preferably, the assembly comprises a plurality of corrugated sheets 2, of which there may be v any desired number, arranged in alternating relation with the fiat liner sheets 3 disposed in- 25 termediate the corrugated sheets and on oppo site sides of the assembly to afford exteriorv cover sheets therefor.

The corrugated sheets 2 are preferably of dual ply construction. Interposed between the plies 30 2a thereof is a stratum 4 of vapor and moisture resistant material. This may be an asphalt prep-. aration or it may be of phenolic condensation character or a synthetic resinous compound. There are a number of such vapor and moisture 35 repellent materials available on the market, any one of which may be utilized, and therefore the invention is not limited to the use of a particular sealing material. In lieu of such stratumof a water and vapor proof adhesive, such stratum 4 4.0 may be of metallic foil or a water proof or nonabsorbent paper orplastic composition.

An assembly of alternating corrugated and flat liner sheets having been made, wherein the exterior cover sheets are preferably, but not neces- 45 sarily, allowed to protrude slightly beyond the intermediate filler strata, the margins of the assembly extending transversely of the corrugations, being first coated with an adhesive, are pressed and compacted into a rounded form wherein the margins of the opposite cover sheets are joined and sealed over the ends of the corrugations, thereby effectively closing the ends thereof to prevent the entrance of moist air and 55' thereby forminga succession of dead air spaces therein.

For an adhesive sealing material for closing and sealing the margins of the board, either of the materials before mentioned may be utilized or such edges may be coated with a silicate solution, and even a starch paste has been found quite sufiicient for some conditions of use. The method and apparatus for thus closing the marginal edges of the composite or assembled board will form the subject matter of a separate application.

The boards may be formed in any suitable size. But, for convenience of handling, it is found that sections of approximately sixteen inches Wide by forty-eight inches long are quite suitable and easily handled and applied. However, larger or smaller sections may be employed. The invention is not limited as to their size. Such boards are nailed directly to the wall studding or overhead joists of a building construction.

Ordinary mortar plaster is applied thereto in a Wet plastic condition. The liner or cover sheets, being quite porous and absorbent, readily absorb moisture from the plaster and by capillary attraction effect an interknit union of the plaster deposit with the fibers of the board. The moisture, however, cannot penetrate entirely through the assembly, but only through the cover sheet and contiguous outer ply of the adjacent corrugated sheet, until it encounters the interposed stratum of moisture and vapor resistant substance which arrests and limits the depth of moisture penetration.

While the invention has herein been described primarily for use as a plaster board on which to apply an adhesive covering of plaster, mortar or stucco, it is also applicable to other building purposes. For example, in suitable sizes it may be advantageously employed for insulating builtup roofs, particularly fiat type roofs for industrial buildings, and and for houses, and may be used as insulating sheathing beneath exterior brick veneer, wood sheathing and other types of exterior finish materials.

Furthermore, while, for illustrative purpose but without intent to unduly limit its application or scope, the board embodying the present invention is illustrated as comprising only two corrugated layers or strata interposed between three flat liner sheets or strata, it is to be understood that the thickness may be either reduced or increased. It may comprise but a single corrugated sheet with an interposed membrane seal between two exterior liner sheets for use between subfiooring and finish flooring in homes and buildings. In such use it dampens sound as well as affords thermal insulation, and may be used in lieu of building felt now employed for such purposes.

In assemblies of increased thickness, threefourths of an inch thickness is found to possess insulating qualities substantially equivalent to three inches of rock wool material. In either of these applications the membrane seal of moisture resistant material intermediate parallel contacting duplex plies of either or both the cor-' rugated and flat sheet material is highly advantageous.

In assemblies of increased thickness up to several inches or more, embodying several membrane seal strata of moisture and vapor-proof material as described, the assembly may be utilized for thermally insulating refrigerators, cold storage compartments and refrigerated display cabinets where it takes the place of asphalt treated cork blocks. In manufacturing the assembly of alternating corrugated duplex sheets having moisture repellant membrane seal strata therebetween and flat liner sheets which may or may not be formed of duplex plies with interposed membrane sealing strata, thealternating flat and corrugated sheets may be stacked to any desired height and the margins sealed by passing them between successive compression rollers and heated shoes of proportionate dimensions.

It is to be further understood that the marginal sealing of the board assemblies by contraction of their edges into rounded adherent formation is effected parallelwith the marginal corrugations as well as'transversely thereof. That is to say, the sheets are preferably, although not necessarily, sealed and rounded on all four edges. Such sealing may be effected by hand tooling, but is preferably performed in machines of suitable size, the particular structure of which and the mode of operation will form the subject matter of a companion application for patents.

From the above description it will be apparent that there is thus provided a device of the character described possessing the particular features of advantage beforeenumerated as desirable, but which obviously is susceptible of modification in its form, proportions, detail construction and arrangement of parts Without departing from the principle involved or sacrificing any of its advantages.

While in order to comply with the statute the invention has been described'in language more or less specific as to structural features, it is to be understood that the invention is not limited to the specific features shown, but that the means and construction herein disclosed comprise the preferred form of several modes of putting the invention into effect, and the invention is therefore claimed in any of its forms or modifications within the legitimate and valid scope of the appended claims.

Having thus described our invention, we claim:

1. A plaster base assembly, comprising superposed alternating corrugated sheets united one to another, the corrugated sheets being of multi-ply construction, a stratum of moisture proof sealing material interposed between the plies thereof, and exterior fiat facing sheets of porous moisture absorbent character disposed on opposite sides of the assembly, the longitudinal margins of the assembly transversely of the corrugations thereof being compacted and compressed into meeting relation of the exterior porous absorbent facing sheets and said margins being sealed, thereby preventing entrance of atmospheric air into the channels'of the corrugations.

2. A vapor and moisture-proof plaster base, including alternating superposed fiat and corrugated' plies of fibrous sheet material, a stratum of vapor and moisture repellant material interposed between contiguous plies thereof, flat exterior porous absorbent facing sheets on opposite sides of the assembly, and longitudinal sealed margins of the assembly extending transversely of the corrugations thereof, formed by uniting the porous absorbent facing sheets, closing the ends of the corrugation channels and forming dead air cells within the structure.

3. A plaster base assembly, comprising alternating superposed flat and corrugated sheets of fibrous material, the external sheets of which are both flatand of porous absorbent character, said external porousabsorbent sheets being marginally united one to the other about the intermediate corrugated sheets and sealed along those edges of the board extending transversely of the corrugations.

4. A vapor and moisture-proof plaster board, comprising alternating flat and corrugated sheets of fibrous material, at least one of said sheets being of at least dual ply, a stratum of vapor and moisture repellant material interposed between the plies thereof, facing sheets of porous absorbent material disposed on opposite sides of the assembly, and longitudinal marginal portions of the opposite porous absorbent facing sheets extending transversely of the corrugations into overlapping sealed relation, closing the ends of the corrugation channels and dead air cells within the structure formed thereby.

5. A vapor and moisture-proof plaster base assembly, including alternating flat and corrugated sheets of fibrous material, a stratum of vapor and. moisture repellant material associated with at least one of said sheets and extending coextensively therewith, exterior facing sheets of moisture absorbent material disposed on opposite sides of the assembly, the margins of which are interconnected one with the other about the longitudinal edges of the assembly transversely of the corrugations thereof, and dead air cells formed within the channels of the corrugations thereby.

6. A vapor and moisture-proof plaster base assembly, including alternating flat and corrugated sheets of fibrous material, a stratum of vapor and moisture repellant material associated with at least one of said sheets and extending coextensively therewith, exterior facing sheets of moisture absorbent material disposed on opposite sides of the assembly, sealed margin portions of the structure extending transversely of the corrugations, and dead air cells formed within the channels of the corrugations thereby.

'7. A plaster base assembly, including a cellular core of sheet material including a stratum of vapor and moisture repellant character extending coextensively with the core, and fibrous moisture absorbent exterior cover sheets, the edge of at least one of said sheets being extended about the margin of said core into sealed contact relation with the opposite cover sheet.

8. A plaster base assembly, comprising at least one corrugated sheet of fibrous material, a stratum of vapor and moisture repellant character associated therewith, exterior porous absorbent cover sheets on opposite sides of the corrugated sheet, the margins of which are joined one with the other transversely of the corrugations of the intermediate sheet, and dead air cells formed in the channels of the corrugations thereby.

9. A plaster base, comprising a corrugated cellular core, fibrous moisture absorbent cover sheets disposed on opposite sides of the core and united one with the other along the edges of the assembly transversely of the corrugations of the core, dead air spaces formed thereby within the corrugations of the core, and a stratum of vapor and moisture repellant character coextensive with the assembly incorporated therein intermediate the cover sheets.

10. A corrugated board plaster base, including alternating superposed flat and corrugated sheets of fibrous material, the outermost sheets of which are of porous absorbent character, sealed marginal edges of the assembly extending transversely of the corrugations thereof formed by marginally uniting the outermost porous absorbent sheets one to the other, and dead air cells formed within the channels of the corrugations thereby.

11. A corrugated board plaster base, including alternating superposed fiat and corrugated sheets of fibrous material, including flat porous moisture absorbent outermost sheets, an interposed stratum of vapor and moisture repellant character coextensive with the assembly interposed between said outermost sheets, sealed marginal edges of the assembly extending transversely of the corrugations thereof formed by marginally uniting the porous absorbent outermost sheets, and dead air cells formed within the channels of the corrugations thereby.

12. A corrugated paper board, including outer plane liner sheets of porous moisture absorbent character and an intermediate corrugated sheet, a sealed marginal portion comprising the margins of the porous absorbent outer cover sheets joined one with the other about the margin of the inner corrugated sheet, and dead air cells formed thereby in the channels of the corrugations.

13. An insulating board, comprising outer plane porous moisture absorbent cover sheets and a cellular filler body intermediate the cover sheets and a sealed marginal edge of the assembly comprising the marginal portions of the porous absorbent cover sheets projected beyond the intermediate filler portions and joined one with the other to enclose the cellular filler.

14. An insulating board, comprising outer parallel relatively spaced plane cover sheets of porous moisture absorbent character, a corrugated filler core portion intermediate the cover sheets, a closure for the ends of the corrugation channels comprising the marginal edges of the porous absorbent cover sheets joined one to the other transversely of the corrugations, and dead air cells formed in the channels of the corrugations thereby.

GILBERT R. EICHELBERGER. CHARLES D. ALTICK. VERNER WADE. 

